Vehicular brake rotor with no intermediate coating layer

Abstract

A vehicular brake rotor uses chrome carbide to acquire a higher coefficient of friction without need for an intermediate coat layer. After application of an aluminum bond coat layer, there is applied a second (of only two) layers comprised of ceria-stabilized zirconium, said layer comprising a 20-50 wt. % mixture of Ni—Al bond coat and zirconium and a 5-30 wt. % of chrome carbide.

What is claimed is: 
     
         1 . A vehicle brake rotor having a bond coat of nickel-aluminum and a top coat of nickel-aluminum mixed with ceria-stabilized zirconium oxide and chrome carbide. 
     
     
         2 . The brake rotor of  claim 1 , which is made from titanium or a titanium based alloy. 
     
     
         3 . The brake rotor of  claim 1 , which is made from a steel alloy. 
     
     
         4 . The brake rotor of  claim 4 , which is made from stainless steel. 
     
     
         5 . The brake rotor of  claim 1 , which is a single plane rotor. 
     
     
         6 . The brake rotor of  claim 1 , which is a vaned cast rotor. 
     
     
         7 . The brake rotor of  claim 1 , which is a billet vaned rotor. 
     
     
         8 . The brake rotor of  claim 1 , which has no intermediate coating layer applied thereto. 
     
     
         9 . The brake rotor of  claim 1  wherein the nickel-aluminum bond coat is about 0.002 to 0.005 in. thick. 
     
     
         10 . The brake rotor of  claim 9  wherein the bond coat contains about 95 wt. % nickel and 5 wt. % aluminum. 
     
     
         11 . The brake rotor of  claim 1  wherein the top coat is about 0.01 to 0.015 in. thick. 
     
     
         12 . The brake rotor of  claim 1  wherein the top coat contains a mixture with about 20-50 wt. % nickel-aluminum bond coat and ceria-stabilized zirconium oxide. 
     
     
         13 . The brake rotor of  claim 12  wherein the top coat further contains about 5-30 wt. % chrome carbide. 
     
     
         14 . A titanium or titanium alloy vehicular brake rotor having a bond coat of nickel-aluminum and a top coat of nickel-aluminum mixed with ceria-stabilized zirconium oxide and chrome carbide but no intermediate coat layer. 
     
     
         15 . The titanium or titanium alloy brake rotor of  claim 14  wherein the nickel-aluminum bond coat is about 0.002 to 0.005 in. thick. 
     
     
         16 . The titanium or titanium alloy brake rotor of  claim 15  wherein the bond coat contains about 95 wt. % nickel and 5 wt. % aluminum. 
     
     
         17 . The titanium or titanium alloy brake rotor of  claim 14  wherein the top coat is about 0.01 to 0.015 in. thick. 
     
     
         18 . The titanium or titanium alloy brake rotor of  claim 14  wherein the top coat contains a mixture with about 20-50 wt. % nickel-aluminum bond coat and ceria-stabilized zirconium oxide. 
     
     
         19 . The titanium or titanium alloy brake rotor of  claim 18  wherein the top coat further contains about 5-30 wt. % chrome carbide.